Integrally formed roof rack

ABSTRACT

A vehicle roof panel includes a roof portion and roof rack portion with an integrally embossed portion defined by longitudinally extending spaced apart side portions. A side rail is attached to each of the side portions. A cross member has connectors for selectively and slidably interconnecting to the side rail thereby retaining the cross member elevated above the planar surface of the roof panel.

This application claims the benefit of Provisional Application No.60/180,431, filed on Feb. 4, 2000.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to an automotive roof panel. Moreparticularly, the present invention relates to an automotive roof panelhaving an integrally formed roof rack portion.

2. Description of the Related Art

Minivans and sport utility vehicles are commonly purchased from thefactory with a luggage or sport rack mounted on the roof of the vehicle.Currently, the roof racks are separate components from the vehicle bodyand must be assembled either as a separate operation in the factory, orat the dealer, prior to delivery to the customer. An example of such aroof rack is illustrated in U.S. Pat. No. 5,924,614.

Additionally, current roof racks are only available in black. Noattempts have been made to color coordinate the roof rack with the colorof the vehicle.

The typical roof rack structure is a separate assembly that requirespiercing the roof panel structure to attach the roof rack, thereby,allowing a possible ingress for water or other material.

Therefore, it is desirable to produce a one piece roof panel for anautomobile that has a roof rack portion molded into the roof panel.

SUMMARY OF THE INVENTION

The disadvantages of the prior art may be overcome by providing a roofpanel with an integrally molded roof rack.

It is desirable to simplify the manufacturing steps required to producean automobile roof panel with a roof rack, by negating the need toattach a separate roof rack assembly.

According to one aspect of the invention, there is provided a vehicleroof panel assembly comprising a one piece panel having a generallyplanar surface and an embossed portion defined by longitudinallyextending and generally parallel, spaced apart, side portions. At leastone connector is coupled to each of the side portions and at least onecross member extends transversely between the side portions and iscoupled to each of the connectors. The side portions and the connectorselevate and retain the cross member above the planar surface of the roofpanel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially broken perspective view of a roof panel assemblyincorporating the aspects of the present invention; and

FIG. 2 is a partially broken cross-sectional view of the side rails,connectors and cross member of the roof panel assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1 there is shown a roof panel assembly, generallydenoted at 10. The roof panel 10 is preferably formed of a solid body,one piece long-fiber reinforced thermoplastic, such as reinforcedpolypropylene or thermoset plastic. However, it is also possible to diestamp sheet metal in accordance with the present invention.

The roof panel 10 includes a roof portion 12 and a roof rack portion 14.The roof portion 12 includes a generally smooth planar area 16 with anappropriate curvature or contour, according to the vehicle design andspecifications, which terminates at the front at a windshield opening18.

The windshield opening 18 is provided with an appropriate flangestructure 20 such that a glass windshield and seal can be mounted flushwith the roof panel 10. In the illustrated embodiment, the roof portion12 includes a pillar portion 22 for integrating and connecting with thestructural A-pillar of the vehicle.

It is to be understood that the pillar portion 22 can be removed fromthe roof portion 12, approximately along a line extended from thewindshield opening 18, providing a roof portion 12 that does not includea pillar portion 22.

The roof portion 12 is bounded on its outer peripheral sides by anattachment flange 24 that circumferentially surrounds the entire roofpanel 10, except for region adjacent to the windshield opening 18. Theattachment flange 24 is provided to allow an area to attach the roofpanel 10 to the underlying roof structure as well as to provide alocation for other body panels to intersect with the roof panel 10.

The roof rack portion 14 includes a raised or embossed portion 26defining the periphery of the roof rack portion 14. In the illustratedembodiment, the raised portion 26 has a front section 28 and two spacedapart, generally parallel and opposing side sections 30, 32 defining theroof rack portion 14. It is to be understood that a fourth rear section,can be utilized should the roof rack portion 14 not be located at therear most end of the roof panel 10. The fourth rear section, ifincluded, would complete the boundary of the roof rack portion 14.Alternatively, the roof rack portion 14 could include only the two sidesections 30, 32.

Each raised side portion 30, 32 projects upwardly from the planarsurface 16 of the roof portion 12 and extending longitudinally betweenopposite first and second ends 34, 36. Each raised side portion 30, 32further includes an outside surface 38 and an inside surface 40. Theoutside surface 38 has an appropriate radius of curvature to provide anaerodynamic transition to the roof portion 12 and the attachment flange24. An appropriate radius is based on the aesthetics of the roof rackdesign as well as other considerations, such as, the necessary height ofthe raised portion 26, and the appropriate wind resistance qualities ofthe raised portion 26.

The inside surface 40 provides a transition to the roof rack portion 14.The interior surface 40 of the two side portions 30, 32 have integrallyformed pockets 42, 44 created or recessed therein for receiving andsecuring a side rail 46 to each of the side portions 30, 32. The pockets42, 44 define an elongated channel having a generally U-shapedcross-section and extending between the first and second ends 34, 36 ofthe side portions 30, 32.

Referring to FIGS. 1 and 2, the side rail 46 is preferably formed ofmetal to withstand the wear and forces placed upon it during use. Eachside rail 46 extends longitudinally between opposing first and secondends 48, 50 and has a generally C-shaped cross section with a channel 52formed therein for receiving a connector 54. The side rails 46 furtherinclude a plurality of spaced apart notches, or slots, 56 formed ineither the top or bottom edge of the channel defining an adjustmentboundary 57 therebetween to positively locate and secure connector 54 tothe side rail 46. The side rails 46 can be molded into the pockets 42,44 during the molding operations or the side rails 46 may be attached orbonded inside the pockets 42, 44 after the roof panel has been formed.

A connector 54 is designed to slidably engage each of the respectiveside rails 46 via the channel 52 to allow for slidable movement of theconnector 54 between the first and second ends 48, 50 of the side rails46. The connector 54 includes a rail engagement portion 58 having agenerally T-shaped cross section for corresponding mating engagementwithin the C-shaped channel 52 to facilitate the sliding engagement ofthe connector 54 with the side rail 46. Further, the rail engagementportion 58 includes a spring bias locking tab 60 for engaging one of thenotches 56 in the side rail 46, to positively lock the connector 54 inplace along the longitudinal length of the side rail 46.

The connector 54 further includes an arcuate shaped extension neckportion 62 extending outwardly from the rail engagement portion 58 andterminating at a distal cross bar engagement portion 64. The engagementportion 64 is generally rectangular in cross section and stepped downfrom the neck portion 62 forming a male end fitting. The neck portion 62and the engagement portion 64 are designed to allow attachment of anelongated cross bar 66 that transversely extends across the roof rackportion 14 and between the side rails 46 in the opposing side sections30, 32. The cross bar 66 extends between opposite distal ends andincludes a generally hollow rectangular or oval cross sectional shape.The engagement portion 64 is received in ends of the cross bar 66 in atelescoping male/female type arrangement. The cross bar 66 may befixedly attached to the connectors 54 by any type of fastener 68, suchas a screw, as depicted in the drawing, or may be attached using otherconventional means, including rivets, lock pins, or the like.

The cross bar 66 is preferably made of metal and has a slot 70 formed inthe center of the top surface thereof extending the length of the crossbar 66. The slot 70 allows for the attachment of accessories to the roofrack, such as a bicycle rack, ski rack or other similar devices. Theroof panel 10, and specifically, the roof rack portion 14 may includeone or more cross bars 66 slidably coupled between the side sections 30,32 via the connectors 54 in a parallel arrangement.

The roof rack portion 14 further includes a generally planar centralportion 72 that is within the interior periphery defined by the raisedportion 26. The central portion 72 has a plurality of spaced apart andgenerally parallel raised skid channels 74 formed therein to provide askid plate or raised area such that items placed in the roof rackportion 14 will not rub on the central portion 72. The raised skidchannels 74 also serve to strengthen the roof rack portion 14 andprovide heightened rigidity to support the forces exerted upon it whencarrying an item.

The roof rack portion 14 also includes a brake light platform 76 onwhich a central or third brake light (CHMSL) that is required on mostvehicles can be mounted. It is to be understood that the roof rackportion 14 can be formed without the brake light platform 76.

In use, the cross bars 66 are slidably adjustable along the side rails46 by depressing or releasing the locking tabs 60 and moving theopposing connectors 54 to desired corresponding locations on theopposing side rails 46 defined by the notches 56. The locking tabs 60are then released to engage with a corresponding notch 56 to lock theconnectors 54 in place along the side rails 46. In this manner, thespacing of the cross bars 66 can be customized to accommodate amultitude of orientations for various uses.

While the invention has been illustrated in detail in the drawings andin the foregoing description, the same is to be considered asillustrative and not restrictive in nature. It is understood that onlythe preferred embodiments have been shown and described fully and thatall changes and modifications that come within the spirit of theinvention are desired to be protected.

Thus, it is to be appreciated from the preceding disclosures that therehas been described a roof panel having an integrally formed roof rackportion.

1. A vehicle roof panel assembly comprising: an integrally formed onepiece panel having a generally planar surface and an embossed portiondefined by longitudinally extending and generally parallel, spaced apartside portions; at least one connector coupled to each of said sideportions; at least one cross member extending transversely between saidside portions and coupled to said connectors, wherein said side portionsand said connectors space said cross member from said planar surface; anelongated side rail fixedly attached to each of said side portions forslidably connecting said cross member and said connectors to said sideportions; and an elongated pocket forming a recessed channel in each ofsaid side portions for receiving and supporting said side rail.
 2. Avehicle roof panel assembly as set forth in claim 1 wherein saidconnectors are slidably coupled to said respective side portion forproviding selective sliding adjustment of said cross member along thelongitudinal length of said side portions.
 3. A vehicle roof panelassembly as set forth in claim 2 wherein each of said side portionsincludes an inside surface spaced apart from an outside surface, saidelongated pocket formed in said inside surface for receiving said siderail and slidably connecting said cross member and said connectors tosaid side portions.
 4. A vehicle roof panel assembly as set forth inclaim 3 wherein each of said elongated pockets includes a generallyU-shaped cross-section defining said recessed channel for receiving andsupporting said side rail.
 5. A vehicle roof panel assembly as set forthin claim 4 wherein said side rail includes a generally C-shapedcross-section defining an elongated channel and said connector includesa rail engagement portion having a generally T-shaped cross-section forsliding and interlocking engagement in said channel of said side rail.6. A vehicle roof panel assembly as set forth in claim 5 wherein saidside rail includes a plurality of spaced apart notches therein forcooperative engagement with a locking tab coupled to said connector forreleasably locking said connector along said side rail.
 7. A vehicleroof panel assembly as set forth in claim 6wherein each of saidconnectors includes an extension neck portion extending from said railengagement portion from said channel for supporting said cross memberabove said planar surface of said roof panel.
 8. A vehicle roof panelassembly as set forth in claim 7 wherein said roof panel assemblyincludes a roof portion defined by said planar surface and a roof rackportion defined by said embossed side portions.
 9. A vehicle roof panelassembly as set forth in claim 8 wherein said roof panel assemblyincludes a plurality of spaced apart and generally parallel raised skidchannels protruding from said planar surface.
 10. A vehicle roof panelassembly as set forth in claim 9 wherein said roof panel is formed of asolid long-fiber reinforced thermoplastic.
 11. A vehicle roof panelassembly as set forth in claim 9 wherein said roof panel is formed of astamped sheet metal.